Apparatus and method for making an ear warmer and an ear warmer frame

ABSTRACT

An ear warmer comprises a set of membranes and a frame. The set of membranes collectively defines an outer perimeter. The set of membranes is attached along the outer perimeter to define an attachment portion. The attachment portion is entirely disposed within an interior of the set of membranes. The frame is disposed within the interior of the set of membranes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of PCT Application Ser. No.PCT/US01/11041, entitled “Apparatus and Method For Making an Ear Warmerand an Ear Warmer Frame,” filed Apr. 5, 2001, which has been publishedas International Publication No. WO01/76402A1 on Oct. 18, 2001, thedisclosure of which is incorporated by reference in its entirety, whichis a continuation-in-part of U.S. patent application Ser. No.09/521,241, entitled “Apparatus and Method for Making an Ear WarmerHaving Interior Seams,” filed Apr. 5, 2000, now U.S. Patent No.6,332,223 B1, the disclosure of which is incorporated by reference inits entirety. This application is related to U.S. patent applicationSer. No. 09/978,591, entitled “Apparatus and Method for Making an EarWarmer Having Interior Seams,” filed Oct. 18, 2001, the disclosure ofwhich is incorporated by reference in its entirety.

BACKGROUND

The present invention relates to an ear warmer device. Morespecifically, the present invention relates to an apparatus and a methodfor making an ear warmer having interior seams and an ear warmer frame.

SUMMARY OF THE INVENTION

An ear warmer comprises a set of membranes and a frame. The set ofmembranes collectively defines an outer perimeter. The set of membranesis attached along a portion of the outer perimeter or the entire outerperimeter to define an attachment portion. The attachment portion isentirely disposed within an interior of the set of membranes. The frameis disposed within the interior of the set of membranes.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a set of membranes for use in constructing an earwarmer, according to an embodiment of the present invention.

FIG. 2 illustrates an arrangement of an ear warmer shell during aninterim step in an assembly process, according to an embodiment of thepresent invention.

FIGS. 3, 4 and 5 illustrate top views of the ear warmer shell of FIG. 2at different steps in a method for assembling an ear warmer, accordingto an embodiment of the present invention.

FIG. 6 illustrates a top view of a frame that can be disposed within anear warmer shell to form an ear warmer, according to an embodiment ofthe present invention.

FIG. 7 illustrates a frame member of a frame to be inserted into an earwarmer shell, according to an embodiment of the present invention.

FIG. 8 illustrates ear membranes according to an alternative embodimentof the present invention.

FIG. 9 illustrates a top view of a left portion of an ear warmer,according to an embodiment of the present invention.

FIG. 10 illustrates a top view of an ear warmer shell, according toanother embodiment of the present invention.

FIG. 11 illustrates internal components of an ear warmer shell,according to yet another embodiment of the present invention.

FIG. 12 illustrates a set of membranes for use in constructing an earwarmer, according to another embodiment of the present invention.

FIG. 13 illustrates a membrane for use in constructing an ear warmer,according to yet another embodiment of the present invention.

FIGS. 14-15 illustrate a frame for use in constructing an ear warmer,according to another embodiment of the invention.

FIGS. 16A-B illustrate a frame for use in constructing an ear warmer,according to another embodiment of the invention.

FIGS. 17-20B illustrate a frame for use in constructing an ear warmer,according to another embodiment of the invention.

FIGS. 21-23 illustrate a frame for use in constructing an ear warmer,according to another embodiment of the invention.

FIGS. 24-25 illustrate a set of membranes for use in constructing an earwarmer, according to another embodiment of the invention.

FIG. 26 illustrates a set of membranes for use in constructing an earwarmer, according to another embodiment of the invention.

FIGS. 27-29 illustrate a set of membranes for use in constructing an earwarmer, according to another embodiment of the invention.

FIG. 30 illustrates a set of membranes for use in constructing an earwarmer, according to another embodiment of the invention.

FIG. 31 illustrates a set of membranes for use in constructing an earwarmer, according to another embodiment of the invention.

FIGS. 32-33 illustrate a set of membranes for use in constructing an earwarmer, according to another embodiment of the invention.

DETAILED DESCRIPTION

An ear warmer comprises a set of membranes and a frame. The set ofmembranes collectively defines an outer perimeter. The set of membranesis attached along a portion of the outer perimeter or the entire outerperimeter to define an attachment portion. The attachment portion isentirely disposed within an interior of the set of membranes. The frameis disposed within the interior of the set of membranes.

The term “attachment portion” is defined herein as a portion of the setof membranes between the attachment and the outer edge of the membranes.For example, the ear warmer membranes can be sewn together along theircollective perimeter or a portion of that collective perimeter and thenturned inside out. In such a case, the sewn seam as well as the extraportion of the membranes between the sewn seam and the outer edge of themembranes are inside the ear warmer; the frame can be inserted into theinterior of the membranes. Alternatively, the ear warmer membranes canbe bound along their collective perimeter or a portion of thatcollective perimeter.

As described in greater detail below, the set of membranes may be sewn,bound, or sewn and turned inside out. The set of membranes can becoupled together using a combination of sewing, binding, and sewing andthen turning inside out.

FIG. 1 illustrates a set of membranes for use in constructing an earwarmer, according to an embodiment of the present invention. As shown inFIG. 1, an ear warmer can be constructed from first ear membrane 100,second ear membrane 110, middle membrane 120 and outer membrane 130.Membranes 100 through 130 can be made of various types of materialappropriate for providing warmth while also being comfortable on thewearer's skin. For example, membranes 100 through 130 can be made ofsuch materials as fleece, wool, cotton, foam and/or neoprene.

FIG. 2 illustrates an arrangement of an ear warmer shell during aninterim step in an assembly process, according to an embodiment of thepresent invention. Ear warmer shell 200 includes an arrangement ofmembranes 100 through 130 where they have been attached together viaattachment 140 along the perimeter of the collection of membranes (i.e.,along the perimeter of ear warmer 200). Attachment portion 205 is theportion of membranes 100 through 130 between and including attachment140 and the edge of membranes 100 through 130. For example, when earwarmer membranes 100 through 130 are attached by sewing the membranestogether along a portion of their collective perimeter, attachmentportion 205 is the extra portion of the membranes between the sewn seamand the outer edge of the membranes.

More specifically, ear warmer shell 200 can be constructed by firstdisposing first ear membrane 100 and second ear membrane 110 on top ofouter membrane 130. Middle membrane 120 can then be placed on top of theset of outer membrane 130, ear membrane 100 and ear membrane 110 in thearrangement shown in FIG. 2. Ear membranes 100 and 110, and middlemembrane 120 are on top of each other and outer membrane 130 in thesense that they are ordered in a particular way; the particularorientation of the collection of membranes as shown in the figuresherein are not important. The arrangement of membranes 100 through 130can then be attached along the perimeter of ear warmer 200 viaattachment 140. A portion of the perimeter of ear membrane 100 is notattached to outer membrane 130; this unattached perimeter portion islabeled as 101. Similarly, a portion of the perimeter of ear membrane110 is not attached to outer membrane 130; this unattached perimeterportion is labeled as 111.

As discussed above, a variety of couplings can be used to secure themembranes together. For example, in one embodiment, ear membranes 100and 110 and middle membrane 120 can be bound to outer membrane 130. Inanother embodiment, ear membranes 100 and 110 can be sewn to the outermembrane 130 and turned inside out and the middle membrane 120 can bebound to the outer membrane 130. In an alternative embodiment, themiddle membrane 120 can be sewn to the outer membrane 130 and turnedinside out and the ear membranes 100 and 110 can be bound to outermembrane 130. As apparent, any combination of sewn, bound, and sewn andinside out couplings can be used.

FIGS. 2, 3, 4 and 5 illustrate ear warmer shell 200 at different stepsin a method for assembling an ear warmer, according to an embodiment ofthe present invention. As shown in FIG. 3, ear warmer shell 200 includesa first ear portion 210, a second ear portion 220 and a middle portion230. First ear portion 210 includes opening 240 that is formed by theperimeter portion 101 of ear membrane 100. Similarly, second ear portion220 includes opening 250 that is formed by the perimeter portion 111 ofear membrane 110.

Channel 260 is formed by middle portion 120 and the portion of outermembrane 130 disposed with middle membrane 120. More specifically,middle membrane 120 is attached along two portions 121 and 122 of itsperimeter to outer membrane 130 while the two remaining portions 123 and124 of the perimeter of middle membrane 120 are not attached to outermembrane 130. These unattached perimeter portions of middle membrane 120generally correspond to openings 240 and 250, thus channel 260 is formedbetween the attached perimeter portions of middle membrane 120 fromopening 240 to opening 250.

As shown in FIG. 3, ear portion 210 can be turned inside out throughopening 240. More specifically, line 270 shows the direction in whichear portion 210 should be moved to turn it inside out. The outer edge210A of ear portion 210 is moved through opening 240 so that ear portion210 is turned inside out. In otherwords, an interior formed by earmembrane 100 and outer membrane 130 is turned outward by moving the end210A of ear portion 210 along line 270 through opening 240 and thencompletely turned outward as shown in FIG. 4. In this manner, attachment140 (e.g., an externally sewn seam) along the perimeter of ear portion210 is turned inward so that a portion of the attachment 140 is locatedwithin a newly defined interior portion of ear portion 210.Consequently, this portion of attachment 130 is not visible from theoutside of ear warmer shell 200, and rather is internal to ear warmershell 200.

FIG. 4 illustrates another step for assembling an ear warmer accordingto an embodiment of the present invention. The outer edge 220A of earportion 220 is turned inside out along line 280 so that the outer edgeof ear portion 220 is moved through channel 260 and through opening 240.Once ear portion 220 is partially turned inside out within channel 260,it can be further moved along motion line 280 through the use of anadditional device such as a dowel so that ear portion 220 can completelytransit the channel 260 and be moved through opening 240.

Note that as ear portion 220 is turned inside out as described above inreference to FIG. 4, the middle portion 230 is also turned inside out.In other words, as the outer edge of ear portion 220 is turned insideout, the middle portion 230 is moved through its channel 260 and throughopening 240. Consequently, middle portion 230 is turned inside out sothat the exterior sides of middle portion 230 as shown in FIGS. 2 and 3are now interior to ear warmer shell 200 as shown in FIG. 4.

The unattached portions 125 and 126 of middle membrane 120 can then beplaced through the respective openings 240 and 250 so that the ends ofmiddle membrane 120 (shown, for example, as having tabs in FIGS. 3-5)are not visible from the outside but rather are disposed within theinterior formed by ear membrane 100 and outer membrane 130 on one sideof ear warmer shell 200 and formed by ear membrane 110 and outermembrane 130 are on the other end of ear warmer shell 200. Thus, asshown in FIG. 5, attachment 140 (e.g., the sewn seams) that wasexternally visible as the membranes were initially attached along theouter perimeter of ear warmer shell 200 (as illustrated, for example, inFIG. 2) are now all internal to ear warmer shell 200 and not visiblefrom the exterior as shown in FIG. 5. In such a case, ear warmer shell200 has a different appearance from that disclosed in U.S. Pat. No.5,835,609 while yet being an aesthetically pleasing appearance and alsoobviating the need for binding over an external seam.

FIG. 6 illustrates a top view of a frame that can be disposed within anear warmer shell to form an ear warmer, according to an embodiment ofthe present invention. Frame 300 includes a first frame member 310, asecond frame member 310 and a third frame member 320. Frame member 320can be, for example, a slidably adjustable band having an inner curvedside 321 and an outer curved side 322. U.S. Pat. No. 5,835,609 disclosesan example of frame 300 including frame members 310 and 320 and isincorporated herein by reference (see, e.g., FIGS. 28-38 and theassociated written description in U.S. Pat. No. 5,835,609). Connection15 device 330 (such as a rivet) can attach frame members 310 to framemember 230.

FIG. 7 illustrates a frame member of a frame to be inserted into an earwarmer shell, according to an embodiment of the present invention. Morespecifically, frame member 310 may have any shape that is conducive tobeing comfortably placed against a user's ear. For example, in oneembodiment, frame member 310 has a frusto-conical shape. In anotherembodiment, frame member 310 has a frusto-hemispherical shape.

Frame member 310 can include a connection portion 311. In the embodimentshown in FIG. 7, the connection portion 311 can include a rivet holethat aligns with a similar rivet hole in third frame member 320 (shownin FIG. 6); connection device 330 can then attach frame members 310 toframe member 320 via their respective connection portions 311.Alternatively, a connection portion of a frame member (similar infunction to connection portion 311 and connection device 330 of framemember 300) can be an integral snap-fit connector that complementarilyfits with an associated portion on a band-like frame member (similar toframe member 320).

The unattached frame members of frame 300 can be inserted into earwarmer shell 200 and then attached together by the following steps.First, a frame member 310 can be inserted into ear portion 210 throughopening 240. Similarly, a second frame member 310 can be inserted in earportion 220 through opening 250. Of course, frame members 310 can beoriented with respect to the membranes (and the wearer's head)appropriately; for example, outer membrane 130 can be positioned alongthe rear, outward facing (i.e., not adjacent to the wearer's head) withrespect to the ear warmer. In such a case, the frame members 310 shouldbe inserted into the respective interiors of ear portions 210 and 220such that the relative base of the frame members 310 is disposed towardsthe wearer's ears (i.e., the curvature of frame member 310 is similar tothe wearer's head). Similarly, middle membrane 120 should be disposedinwardly adjacent to the wearer's head when the ear warmer is completelyassembled and worn by the wearer.

In the next step in the method for inserting the frame, frame member 320can be inserted into channel 260 through either opening 240 or 250.Again, frame member 320 should be disposed within channel 260 so thatthe curvature of frame member 320 is similar to the curvature of theuser's head.

The ends of frame members 310 can be connected to the respective ends offrame member 320. Once frame members 310 and frame member 320 areappropriately positioned within the interior of ear warmer shell 200,connection portion 311 of frame member 310 can be disposed throughopening 240 along with the corresponding end of frame member 320 so thatframe member 310 and frame member 320 can be attached by connectiondevices 330. The other end of frame member 320 can likewise be attachedto the other frame member 310.

Once the three frame members are attached to form frame 300, the earwarmer shell 200 can be arranged so that frame 300 is completelydisposed within the interior ear warmer shell 200 and is not visiblefrom the exterior. This can be accomplished, for example, by disposingthe respective connected ends of frame members 310 and frame member 320back into the interior ear warmer shell 200. The tab-like ends of middlemembrane 120 can then be reinserted into openings 240 and 250 so thatthe assembling of the ear warmer including its ear warmer shell 200 andframe 300 is complete.

FIG. 8 illustrates ear membranes according to an alternative embodimentof the present invention. Ear membrane 400, as shown in FIG. 8, includescentral portion 401 and extended portions 402. Likewise, ear membrane410 includes central portion 411 and extended portions 412. Note,although only one extended portion is labeled as 402 for ear membrane400 and, similarly, only one extended portion is labeled 412 for earmembrane 410 in FIG. 8, this notation in FIG. 8 is merely forconvenience and would apply to one or more extended portions asappropriate. In an alternative embodiment, each ear membrane may haveonly one extended portion.

Ear membranes 400 and 410 can be substituted for ear membranes 100 and110 as described in the apparatus and method described above inreference to FIGS. 1-7. In such an embodiment, the perimeter seamsdiscussed in conjunction with FIG. 2 above would be formed along thepartial perimeter of central portion 401 and 411 of ear membranes 400and 410, respectively. In other words, extended portions 402 and 412 ofear membranes 400 and 410, respectively, are disposed outside of thecollective perimeter for the ear warmer shell.

When the ear warmer shell is then turned inside out, for example asdiscussed above in reference to FIGS. 3-5, the extended portions 402 and412 of ear membranes 400 and 410, respectively, are located within theinterior of the ear warmer shell and form an additional layer of fabric.For example, FIG. 9 illustrates the extended portions of the earmembranes forming an added layer of fabric within the interior of theear warmer shell.

More specifically, FIG. 9 illustrates a left portion of an ear warmer,according to an embodiment of the present invention. As illustrated inFIG. 9, the ear portion of the left side of FIG. 9 has the extendedportions 402 (shown in phantom) of ear membrane 400 being disposedwithin the interior of an ear warmer shell such that they form a nearlycontinuous piece of additional fabric. In such a case, the frame member310 (shown in phantom) when inserted into an interior of an ear warmershell can be disposed between extended portions 402 and outer membrane130. In such an embodiment, extended portions 402 provide an extra layerof cushioning fabric that is disposed between frame member 310 and thewearer's head. In other words, in such an embodiment, extended portions402 and 412 in addition to central portions 401 and 411 of ear membranes400 and 410, respectively, are disposed between the wearer and the framemember 310. Extended portions 402 and 412 also prevent the ear membranesfrom pulling around the frame members 310 and keep the perimeter of theear membranes at the edge of the frame members 310.

FIG. 10 illustrates an ear warmer shell according to another embodimentof the present invention. In such an embodiment of ear warmer shell 500,the ear membranes can have a size slightly smaller than thecorresponding portions of the outer membrane. The extra material of theouter membrane portions corresponding to the ear membranes allows theframe (once inserted into the ear warmer shell) to better fit within theear warmer shell 500. In other words, because the frame to be insertedinto the ear warmer shell is curved, the outer curved side (e.g., outercurved side 322 as shown in FIG. 6) of the frame is a greater distancethan the inner curved side (e.g., inner curved side 321 as shown in FIG.6) of the frame. Thus, the extra material of the outer membrane allowsthe ear warmer shell 500 to better fit around the curved shape of theframe.

The method to construct ear warmer shell 500 is similar to thatdescribed above in reference to FIGS. 2-5. Before attaching (e.g., bysewing) the collective perimeter of the membranes, the portion of theouter membrane corresponding to an ear membrane can be pinched inwardlyalong lines 510 to gather the perimeter of the outer membrane to moreclosely match the corresponding perimeter of the ear membrane. Forexample, the portion of the outer membrane corresponding to an earmembrane can be pinched and held inwardly with a clip (such as a binderclip), then the collective perimeter or a portion of the collectiveperimeter of the membranes can be attached. Thus, collective perimeterof the membranes are aligned when the membranes are being attached whileallowing the outer membrane to have extra material so that the frame canbetter fit within the ear warmer shell 500.

FIG. 11 illustrates internal components of an ear warmer shell,according to yet another embodiment of the present invention. Forpurposes of clarity, a covering portion of the ear warmer has beenremoved to show the internal components of the ear warmer. In thisembodiment of an ear warmer shell, pocket membranes 600 and 610 (shownin phantom) are included. In such an embodiment, these additional andseparate membranes, i.e., pocket membranes 600 and 610, can be attached(shown in phantom) along the respective portions of the collectiveperimeter of the ear warmer shell. In other words, pocket membranes 600and 610 are attached to respective portions of outer membrane 130 andeach form a respective pocket into which a frame member 310 can beinserted.

The pocket membranes 600 and 610, provide additional cushioning betweenframe members 310 (shown in phantom) and the head of the user. Pocketmembranes 600 and 610 also prevent the membranes from pulling around theframe members 310 and keep the perimeter of the membranes at the edge ofthe frame members 310. In one embodiment, pocket membranes 600 and 610can be attached on top of the respective ear membranes. Thus, when theear warmer shell is turned inside out (as described above, for example,in reference to FIGS. 3-5), pocket membranes 600 and 610 areappropriately positioned within the ear warmer shell. Pocket membranes600 and 610 may be any material that can be coupled to the outermembrane, such as plastic or fabric.

FIG. 12 illustrates a set of membranes for use in constructing an earwarmer, according to another embodiment of the present invention.Similar to the outer membrane 130 and the middle membrane 120 shown inFIG. 1, FIG. 12 illustrates a membrane having an outer portion 730 and amiddle portion 720. The membranes can be arranged as follows. First, theear membranes (e.g., ear membranes 100 and 101) can be placed on thecorresponding portions of outer portion 730, i.e., portions 731 and 732of outer portion 730. Middle portion 720 can then be folded on to outerportion 730 along the line 725. The collective perimeter can then besewn, bound, or sewn and the membranes can be turned inside out asdescribed above in reference to FIGS. 3-5.

FIG. 13 illustrates a membrane for use in constructing an ear warmer,according to yet another embodiment of the present invention. Similar toear membrane 100, ear membrane 110, middle membrane 120 and outermembrane 130 shown in FIG. 1, FIG. 13 illustrates a membrane having earportion 800, ear portion 810, middle portion 820 and outer portion 830.The membrane portions can be arranged as follows. First, the earportions 800 and 810 can be folded on to the corresponding portions ofouter portion 830 along lines 805 and 815, respectively. Middle portion820 can then be folded on to outer portion 830 along the line 825. Thecollective perimeter can then be sewn, bound, or sewn and the membranescan be turned inside out as described above in reference to FIGS. 3-5.

Rather than the separate membranes shown in FIG. 1, variations to FIGS.12 and 13 are possible where certain membranes are integrally formedtogether and folded over. For example, in another embodiment, only oneear membrane is integrally formed with the outer membrane, only two earmembranes are integrally formed with the outer membrane, or only one earmembrane and the middle membrane are integrally formed with the outermembrane.

In another alternative embodiment, the membranes can be integrallyformed together at various locations (e.g., discontinuous locations)rather than along the entire fold (such as line 725 shown in FIG. 12).In yet another embodiment, the membranes can be integrally formed atvarious locations relative to the outer portion of the membrane. Forexample, rather than the ear portions being integrally formed at thelower location of the outer portion (as shown in FIG. 13), the earportions can be integrally formed with the outer portion at otherlocations, such as the side locations 830A and 830B of the outerportion. The various locations that are possible are those where theportions of the membrane (i.e., the middle portion, and/or the earportions) fold on to the outer portion of the membrane to appropriatelyform the ear warmer shell.

FIG. 14 illustrates a frame for use in constructing an ear warmer,according to another embodiment of the present invention. Frame 900includes a first frame member or band 910 and a second frame member orband 940 that can be slidably coupled together to form frame 900, asillustrated in FIG. 15.

In the illustrated embodiment, band 910 includes a first end 912 and asecond end 914. Band 910 includes curved inner and outer surfaces 930,932. Band 910 includes an opening 916 proximate to end 912 to whichanother frame member (not shown in FIGS. 14 or 15) may be coupled, aspreviously discussed. Band 910 also includes a slot 918 extending alongthe length of the band 910. Slot 918 includes ends 920, 922. In theillustrated embodiment, end 920 is a closed end and end 922 is an openend.

Band 910 includes a passageway 926 located proximate to end 914.Passageway 926 includes an opening 928 through which band 940 may beinserted. A retaining member or abutment 924 is disposed on band 910.Abutment 924 extends a sufficient distance from the surface of the band910 so that it engages a connecting or locking member disposed on band940, as discussed in greater detail below. Abutment 924 may be locatedat any location that enables it to engage the locking member. In oneembodiment, abutment 924 is located on the inner surface 930 of band910. In another embodiment, abutment 924 is located along one of theinner surfaces of the slot 918, and thereby extending into the slot 918.While the abutment 924 is illustrated with a triangular shape, theabutment may have any shape or configuration that can retain the bands910, 940 together, as discussed below.

In one embodiment, band 940 includes ends 942, 944 and an opening 952proximate end 944. Band 940 includes inner and outer surfaces 954, 956.Band includes a connecting or locking member 946 on the inner surface954 proximate to end 942. In this embodiment, locking member 946includes a shaft 948 and a head 950. Locking member 946 may be formedintegral with band 940 or may be coupled thereto. Locking member 946 maybe any shape.

In one embodiment, the locking member 946 is fixed relative to band 940.When the frame 900 is assembled, end 942 of band 940 is inserted intopassageway 926 of band 910. The band 940 is pushed with sufficient forceso that locking member 946 engages abutment 924 and passes over theabutment 924. Abutment 924 may have some flexibility to enable thelocking member 946 to pass over it. Once the locking member 946 passesthe abutment 924, the bands 910 and 940 can move relative to each otherand the locking member 946 engages the abutment 924.

In an alternative embodiment, shalt 948 and head 950 are rotatablerelative to the band 940. The locking member 946 can rotate betweenseveral positions. In one position, the head 950 of the locking memberis oriented substantially parallel to the longitudinal axis of the band940. This position can be referred to as a locking position. In anotherposition, the head 950 of the locking member may be oriented at an anglewith respect to the longitudinal axis of the band 940. The angle mayrange between 0 and 90° . This position can be referred to as a slidingposition.

When the frame 900 is assembled, end 942 of band 940 is inserted intopassageway 926 of band 910. Initially, the locking member 946 is rotatedto its sliding position. As band 940 slides through passageway 926, theshaft 948 of locking member 946 slides in slot 918. As band 940 isinserted into passageway 926, the locking member 946 passes the abutment924.

Once the locking member 946 passes the abutment 924, it can be rotatedto its locking position, which is illustrated in FIG. 15. In the lockingposition, head 950 engages abutment 924, thereby retaining bands 910,940 together. The range of movement of band 940 relative to band 910while the bands are coupled together is limited to the distance betweenslot end 920 and abutment 924.

In an alternative embodiment, band 940 can have a hole located wherelocking member 946 is positioned. In this embodiment, a connector, suchas a rivet, can be inserted through the hole and slot 918 to couple thebands 910 and 940 together.

Openings 916 and 952 can be used to couple other frame members (notshown in FIGS. 14 or 15) to the frames 910, 940, as discussed above.While the passageway 926 on band 910 and the locking member 946 on band940 are illustrated on outer surface 932 and inner surface 954,respectively, the passageway 926 and locking member 946 can be locatedon the opposite sides of each of their respective bands.

FIGS. 16A-B illustrate other embodiments of a frame for an ear warmer,according to the present invention. In this embodiment, frame 1000includes bands 1010, 1020 that can be slidably coupled together.

Band 1010 includes a slot 1012 with closed ends 1014, 1016 and apassageway 1018 with an opening 1019 located proximate to an end of theband 1010. In an alternative embodiment, the side surfaces of the slotcan be notched.

Band 1020 includes ends 1024, 1026 and a locking member 1022 proximateto end 1024 similar to the locking member 946 described relative toFIGS. 14-15. As discussed relative to locking member 946, locking member1022 can be either fixed relative to band 1020 or rotatable relative toband 1020.

One method of assembling frame 1000 includes the following steps. Bands1010, 1020 are placed at an angle to each other and locking member 1022is inserted into the slot 1012. If the locking member is spherical, thenthe bands 1010, 1020 can be aligned. Once the locking member 1022 isinserted, the bands 1010, 1020 are turned so that they are substantiallyparallel to each other. Each of the bands 1010, 1020 is made of flexiblematerial that allows the bands to bend in several directions. Then, end1026 of band 1020 is inserted into the opening 1019 of passageway 1018.In an alternative embodiment, band 1010 can be longer than band 1020 tofacilitate the insertion of end 1026 into opening 1019 and the assemblyof the frame 1000.

Bands 1010, 1020 are then slidably coupled together. The range ofmovement of the bands 1010, 1020 is determined by the length of the slot1012.

Another method of assembling frame 1000 includes the following steps.Bands 1010, 1020 are placed adjacent each other so that end 1026 isproximate to passageway 1018 and end 1024 is proximate to the other endof band 1010. End 1026 of band 1020 is inserted into the opening 1019 ofpassageway 1018.

The locking member 1022 is rotated to its sliding position and the headof locking member 1022 is inserted into slot 1012. Because the bands1010, 1020 are made from a flexible material, such as plastic, band 1020can be bent during the assembly process to enable locking member 1022 tobe inserted into slot 1012. Once locking member 1022 is inserted,locking member 1022 is rotated to its locking position, therebypreventing the separation of bands 1010, 1020. Bands 1010, 1020 are thenslidably coupled together. The range of movement of the bands 1010, 1020is determined by the length of the slot 1012.

In an alternative embodiment, as illustrated in FIG. 16B, the bands canalso be coupled together by a connector 1023. Band 1020′ includes a hole1021 through which connector 1023 may be inserted. The use of aconnector establishes a non-releasable connection between the bands.

FIGS. 17 and 18 illustrate another embodiment of a frame for an earwarmer, according to the present invention. In this embodiment, frame1100 includes bands 1110, 1140 that can be slidably coupled together.

Band 1110 includes ends 1112, 1114. Band 1110 also includes a channel1116 with ends 1118, 1120. In the illustrated embodiment, channel end1120 is an open end and channel end 1118 is a closed end. Band 1110 alsoincludes a passageway 1126 located proximate to end 1114. Passageway1126 includes an opening 1128 through which band 1140 can be inserted.Channel 1116 extends substantially along the length of band 1110.

Channel 1116 includes inner side surfaces 1122, 1124 that are curvedalong their length. In one embodiment, inner side surfaces 1122, 1124have a convex shape as illustrated in the cross-sectional view shown inFIG. 19B. In an alternative embodiment, inner side surfaces 1122′, 1124′have a concave shape as illustrated in the cross-sectional view shown inFIG. 20B.

Band 1140 includes ends 1142, 1144 and inner and outer surfaces 1146,1147. In one embodiment, a locking nub 1148 is disposed on outer surface1147, as illustrated in FIG. 18. The locking nub 1148 engages passageway1126 after the bands 1110, 1140 are coupled together to retain them in acoupled configuration.

Band 1140 includes side surfaces 1150, 1152 that extend along the lengthof the band 1140 as illustrated in FIG. 19A. Side surfaces 1150, 1152are curved along their length. In one embodiment, side surfaces 1150,1152 have a concave shape as illustrated in the cross-section view shownin FIG. 19A. In an alternative embodiment, side surfaces 1150′, 1152′have a convex shape as illustrated in the cross-sectional view shown inFIG. 20A.

As band end 1140 is inserted into channel 1116, side surfaces 1150, 1152engage inner side surfaces 1122, 1124 on band 1110. The frictionalcontact between the side surfaces on bands 1110, 1140 provides thenecessary force to retain the bands together.

FIG. 21 illustrates another embodiment of a frame for an ear warmer,according to the present invention. Frame 1300 includes bands 1310, 1330that can be slidably coupled together. Band 1310 includes ends 1312,1314 and a slot 1316 extending substantially along the length of band1310. In this embodiment, slot 1316 includes closed ends 1312, 1320.Band 1310 includes a connecting member or retaining member 1322 disposedon its inner surface as illustrated in FIG. 22.

Band 1330 includes ends 1332, 1334 and a slot 1336 extendingsubstantially along the length of band 1330. Slot 1336 includes closedends 1338, 1340. Band 1330 also includes a locking member 1342 disposedon its outer surface as illustrated in FIG. 23. In one embodiment,locking member 1342 is fixed relative to the band 1330. In anotherembodiment, locking member 1342 rotates relative to the band 1330.

Frame 1300 is assembled by inserting the locking member 1342 on band1330 into slot 1316 on band 1310. Depending on the structure of thelocking member 1342, band 1310 is turned perpendicular to band 1330 orlocking member 1342 is rotated relative to band 1330. Once the lockingmember 1342 has been inserted, the retaining member 1322 on band 1310 isinserted into slot 1336 of band 1330. At this point, bands 1310, 1330can slide relative to each other. The movement of bands 1310, 1330 islimited by the length of slots 1316, 1336 and the positions of retainingmember 1322 and locking member 1342 on the bands 1310, 1330,respectively.

Retaining member 1322 and locking member 1342 can be any shape that canbe inserted into a slot and couple the bands together. Alternatively,connectors, such as rivets, may be used instead of one or both of theretaining member and the locking member to couple the bands.

FIGS. 24 and 25 illustrate a membrane for use in constructing an earwarmer, according to another embodiment of the present invention.Similar to ear membrane 100, ear membrane 110, middle membrane 120, andouter membrane 130 illustrated in FIG. 1, FIGS. 24 and 25 illustrate ashell 1400 having ear membrane 1410, ear membrane 1420, middle membrane1430, and outer membrane 1440.

One method by which the shell 1400 can be assembled is the following.Ear membrane or portion 1410 can be coupled to one end of the outermembrane or portion 1440. Similarly, ear membrane or portion 1420 can becoupled to the opposite end of outer membrane 1440. Middle membrane orportion 1430 is coupled to the perimeter of outer membrane 1440. Thecollective perimeter can be sewn, bound, or sewn and the membranes canbe turned inside out as described in above in reference to FIGS. 3-5.

In this embodiment, middle portion 1430 includes a coupling mechanism1460 disposed along one of its edges. The outer portion 1440 includes asimilar coupling mechanism 1462 along a portion of its perimeter asillustrated in FIG. 24. Once a frame has been inserted into membrane1400, the coupling mechanisms 1460, 1462 can be coupled together tosecure the middle portion 1430 to the outer portion 1440 and close theinterior of the shell 1400.

Coupling mechanisms 1460, 1462 can be any type of fastening mechanismthat permanently or releasably couples the middle portion and the outerportion. For example, coupling mechanisms 1460, 1462 can be hook andloop type fasteners. Alternatively, any mechanism that can couple twopieces of fabric together can be used for the coupling mechanisms.Similarly, the middle portion 1430 can be sewn to the outer portion1440.

Shell 1400 enables a fully-assembled frame to be inserted after theshell is sewn. Shell 1400 also enables shells to be changed on the sameframe.

FIG. 26 illustrates an alternative shell for use in constructing an earwarmer according to another embodiment of the present invention.Membrane 1500 includes ear portions 1512, 1514, and an outer membrane1520. In the illustrated embodiment, as shown in FIG. 26, middle portion1516 is integrally formed with the outer membrane 1520. Middle portion1516 can include a coupling mechanism 1518 located proximate one of itsedges.

Outer membrane 1520 includes a coupling mechanism 1522 that can be usedwith coupling mechanism 1518 on the inner membrane 1510 to secure middleportion 1516 to the outer membrane 1520.

FIGS. 27-29 illustrate an alternative shell for use in constructing anear warmer, according to an embodiment the present invention. Membrane1600 includes an inner membrane 1610 and an outer membrane 1620. In thisembodiment, inner membrane 1610 has a different shape than outermembrane 1620. Outer membrane 1620 has a thicker middle portion thaninner membrane 1610 as illustrated in FIG. 28. Outer membrane 1620provides additional protection for a neck of a user, as illustrated inFIG. 29.

FIG. 30 illustrates another shell for use in constructing an ear warmer,according to an embodiment of the present invention. Shell 1700 includesan inner membrane 170 and an outer membrane 1720. Inner membrane 1710 isattached along a portion 1711 of its perimeter to outer membrane 1720while the remaining portion 1712 of the perimeter of the inner membrane1710 is not attached to outer membrane 1720. The unattached perimeterportions of inner and outer membranes 1710, 1720 generally correspond toopening 1730 as illustrated in FIG. 30.

A frame for the ear warmer can be inserted through opening 1730 andpositioned in the interior region of the shell to support the earwarmer. Once the frame is inserted, opening 1730 can be left open or canbe closed by any conventional coupling mechanism, such as sewing, hookand loop fasteners, etc. The frame can be assembled before or aftersewing the shell together.

FIG. 31 illustrates another shell for use in constructing an ear warmer,according to the present invention. Shell 1800 includes an innermembrane 1810 and an outer membrane 1820. The extent that the perimetersof inner and outer membranes 1810, 1820 are coupled together can vary todefine one or more openings.

Inner membrane 1810 is attached along two portions 1812, 1814 of itsperimeter to outer membrane 1820 while the two remaining portions 1816,1818 of the perimeter of the inner membrane 1810 are not attached toouter membrane 1820. These unattached perimeter portions 1816, 1818 ofinner membrane 1810 generally correspond to openings 1830, 1832,respectively.

A frame can be inserted into one or both of the openings 1830, 1832 andcan be subsequently assembled while it is inside the interior region.Openings 1830, 1832 can be left open or be closed using any couplingmechanism.

FIGS. 32-33 illustrate a shell for use in constructing an ear warmer,according to the present invention. Shell 1900 includes inner membranes1910, 1920 and outer membrane 1930. Inner membrane 1910 includes ends1912, 1914. Similarly, inner membrane 1920 includes ends 1922, 1924. Theinner membranes 1910, 1920 function as the ear portions of the shellwhen the membranes are connected together. The perimeter portions ofinner membranes 1910, 1920 can be coupled to the perimeter portion ofouter membrane 1930, thereby defining an interior region into which aframe can be inserted.

In one embodiment, ends 1914, 1922 of membranes 1910, 1920 are curved.When membranes 1910, 1920, 1930 are assembled, as illustrated in FIG. 36an opening 1940 is defined by ends 1914, 1922 which are locatedproximate to each other. A frame can be inserted into the interiorregion 1950 of membrane 1900 through opening 1940. Opening 1940 can beleft open or can be covered by another piece of material. In oneembodiment, the ends 1914 and 1922 contact each other. In anotherembodiment, the ends 1914 and 1922 may be spaced apart from each other.

It should, of course, be understood that while the present invention hasbeen described in reference to particular configurations, otherconfigurations will be apparent to those of ordinary skill in the art.For example, the membranes and frame members can be made of any type ofmaterials appropriate for an ear warmer device. U.S. Pat. No. 5,835,609,the disclosure of which is incorporated herein by reference, disclosesvarious embodiments of the ear warmer device and those variation can becombined with the method and apparatus described herein.

What is claimed is:
 1. An ear warmer frame comprising: a first bandhaving a slot, said first band including a first ear warmer frame membercoupled to an end of said first band; and a second band slidablycoupleable to said first band, said second band including a second earwarmer frame member coupled to an end of said second band, said secondband including a connecting member for selectively engaging said slot tocouple said second band and said first band, said connecting memberbeing configured to be inserted into said slot and being configured tocouple said first and second bands.
 2. The ear warmer frame of claim 1wherein said slot includes an open end.
 3. The ear warmer frame of claim1 wherein said slot includes an open end, said first band including aretaining member, said retaining member being engageable with saidconnecting member when said first and second bands are coupled together.4. The ear warmer frame of claim 1 wherein said first band includes afirst end and a second end, said first band including a passagewayproximate said first end.
 5. The ear warmer frame of claim 1 whereinsaid first band includes a first end and a second end, said first bandincludes a passageway proximate said first end, and said slot includesan open end proximate said first end.
 6. The ear warmer frame of claim 1wherein said first band includes a coupler, said second band includes aslot, said coupler being coupleable with said second band slot.
 7. Theear warmer frame of claim 1 wherein said first band includes a coupler,said second band includes a slot, said coupler being coupleable withsaid second band slot, said second band slot being closed at both ends.8. The ear warmer frame of claim 1 wherein said connecting member isrotatable relative to said second band between an inserting position anda retaining position, said connecting member being configured to beinserted into said slot in said inserting position and configured tocouple said first and second bands in said retaining position.
 9. Amethod of assembling an ear warmer frame, the ear warmer frame includinga first band having a longitudinal direction, the first band including aconnecting member disposed thereon, and a second band having alongitudinal direction, the second band defining a slot, said methodcomprising: inserting the connecting member of the first band into theslot of the second band; and disposing the connecting member and thefirst band relative to the second band to position the first and secondbands in a substantially aligned configuration along their longitudinaldirections.
 10. The method of claim 9, the second band including apassageway at one end, said method further comprising: inserting thefirst band through the passageway of the second band.
 11. The method ofclaim 10, wherein said inserting the connecting member occurs prior tosaid inserting the first band.
 12. The method of claim 9, the first banddefining a slot, the second band including a coupler, said methodfurther comprising: inserting the coupler into the first band slot. 13.The method of claim 9, wherein said inserting the connecting memberoccurs prior to said disposing the connecting member, and said disposingthe connecting member and the first band includes rotating the firstband into alignment with the second band.
 14. The method of claim 9,wherein said disposing the connecting member and the first band includesrotating the connecting member relative to the first band.
 15. An earwarmer comprising: a shell including: an outer membrane defining aperimeter; an inner membrane attached to said outer membrane, said outermembrane and said inner membrane defining an interior portion of saidshell, said inner membrane attached along a substantial portion of saidperimeter, said outer membrane and said inner membrane defining anopening therebetween along said perimeter, said opening being incommunication with said interior portion, said inner membrane includinga first ear portion, a second ear portion, and a middle portion; and aframe configured to be inserted through said opening and into saidshell.
 16. The ear warmer of claim 15, wherein said opening is along aportion of said middle portion.
 17. The ear warmer of claim 15, whereinsaid opening is along a portion of said first ear portion.
 18. The earwarmer of claim 15, wherein at least one of said outer membrane and saidinner membrane includes a coupling mechanism, and said couplingmechanism is configured to close said opening.
 19. The ear warmer ofclaim 15, wherein said inner membrane and said outer membrane define aplurality of openings therebetween along said perimeter, said pluralityof openings being in communication with said interior portion.
 20. Anear warmer comprising: a shell including: an outer membrane defining aperimeter, said outer membrane having a first ear portion and a secondear portion; a first inner membrane attached to said outer membranealong a first portion of said perimeter, said first inner membrane beingpositioned proximate to said first ear portion, said first innermembrane having a first end and a second end; and a second innermembrane attached to said outer membrane along a second portion of saidperimeter, said second inner membrane being positioned proximate to saidsecond ear portion, said second inner membrane having a first end and asecond end, said outer membrane, said first inner membrane, and saidsecond inner membrane defining an interior region therebetween, saidsecond end of said first inner membrane being proximate to said secondend of said second inner membrane, said second ends defining an openingto said interior region therebetween; and a frame configured to beinserted through said opening in said shell.
 21. The ear warmer of claim20, wherein said second end of said first inner membrane is in contactwith said second end of said second inner membrane.
 22. An ear warmershell, comprising: an outer membrane defining a perimeter; a first earmembrane attached to said outer membrane along a first portion of theperimeter and defining a first interior portion of the ear warmer shell,said first ear membrane being attached within the first interiorportion; a second ear membrane attached to said outer membrane along asecond portion of the perimeter and defining a second interior portionof the ear warmer shell, said second ear membrane being attached withinthe second interior portion; and a middle membrane attached to saidouter membrane along a third portion of the perimeter and defining athird interior portion of the ear warmer shell, said middle membranebeing coupleable to said outer membrane along a fourth portion of theperimeter.
 23. The ear warmer of claim 22, wherein said middle membraneis releasably coupleable to said outer membrane along said fourthportion.
 24. The ear warmer of claim 23, wherein said middle membraneincludes one of a hook and loop fastener proximate an end and said outermembrane includes the other of a hook and loop fastener proximate saidfourth portion.
 25. The ear warmer of claim 22, wherein said middlemembrane is sewn to said outer membrane along said fourth portion. 26.An ear warmer having an outer perimeter, comprising: plurality ofmembrane portions, the plurality of membrane portions being coupledtogether to define the outer perimeter of the ear warmer, the pluralityof membrane portions being attached along the outer perimeter of the earwarmer to define an attachment portion, at least a portion of theattachment portion being disposed within an interior of the plurality ofmembrane portions; and a frame disposed within the interior of theplurality of membrane portions.
 27. The ear warmer of claim 26, whereinthe attachment portion of said plurality of membrane portions includes acoupling mechanism that releasably couples membrane portions.
 28. Theear warmer of claim 26, wherein a first membrane portion of theplurality of membrane portions and a second membrane portion of theplurality of membrane portions are bound together.
 29. A method forassembling an ear warmer having a band and a membrane with a pluralityof membrane portions, the plurality of membrane portions including afirst ear portion, a second ear portion, a middle portion and an outerportion, said method comprising: coupling the middle portion to theouter portion; turning inside out the middle portion and the outerportion; and disposing the band proximate to the middle portion.
 30. Themethod of claim 29, wherein said coupling the middle portion includescoupling the middle portion to the outer portion along one side of themiddle portion.
 31. The method of claim 29, wherein said coupling themiddle portion includes coupling the middle portion to the outer portionalong a plurality of sides of the middle portion.
 32. The method ofclaim 29, wherein said coupling the middle portion includes sewing themiddle portion to the outer portion.
 33. The method of claim 29, furthercomprising: coupling the first ear portion to the outer portion; andcoupling the second ear portion to the outer portion.
 34. The method ofclaim 29, wherein said coupling the middle portion occurs prior to saiddisposing the band.
 35. An ear warmer frame, comprising: a first bandhaving a slot; a second band slidably coupleable to said first band,said second band including a hole; a connector extending through saidhole on said second band and said slot on said first band, saidconnector coupling said first and second bands; a first ear warmer framemember coupled to an end of said first band; and a second ear warmerframe member coupled to an end of said second band.
 36. A method ofassembling an ear warmer shell, the shell including an outer membranedefining a perimeter, a first inner membrane having a first end and asecond end, a second inner membrane having a first end and a second end,the outer membrane, the first inner membrane, and the second innermembrane defining an interior region therebetween, the second end of thefirst inner membrane being proximate to the second end of the secondinner membrane, the second ends defining an opening to the interiorregion, the method comprising: coupling the first inner membrane to saidouter membrane along a first portion of said perimeter; coupling thesecond inner membrane to said outer membrane along a second portion ofsaid perimeter; and inserting a frame into the opening and into theshell.
 37. A method of assembling an ear warmer shell, the shellincluding an inner membrane, and an outer membrane defining a perimeter,the outer membrane and the inner membrane defining an interior portionof the shell, the inner membrane including a first ear portion, a secondear portion, and a middle portion, the method comprising: coupling theinner membrane to the outer membrane along a substantial portion of theperimeter, the outer membrane and the inner membrane defining an openingtherebetween along the perimeter, the opening being in communicationwith the interior portion and located along the perimeter; and insertinga frame into the opening and into the shell.
 38. The method of claim 37,wherein the inner membrane includes a first coupling mechanism and theouter membrane includes a second coupling mechanism, the first andsecond coupling mechanisms being configured to be coupled and close theopening.
 39. An ear warmer frame comprising: a first band having a slot;and a second band slidably coupleable to said first band, said secondband including a connecting member for selectively engaging said slot tocouple said second band and said first band, said connecting memberbeing configured to be inserted into said slot and being configured tocouple said first and second bands, said slot includING an open end,said open end permitting passage of said connecting member.
 40. An earwarmer frame comprising: a first band having a slot and a coupler; and asecond band slidably coupleable to said first band, said second bandincluding a connecting member for selectively engaging said first bandslot to couple said second band and said first band, said connectingmember being configured to be inserted into said first band slot andbeing configured to couple said first and second bands, said second bandincluding a slot, said coupler being coupleable with said second bandslot.
 41. An ear warmer frame comprising: a first band having a slot;and a second band slidably coupleable to said first band, said secondband including a connecting member for selectively engaging said slot tocouple said second band and said first band, said connecting memberbeing configured to be inserted into said slot and being configured tocouple said first and second bands, wherein said connecting member isrotatable relative to said second band between an inserting position anda retaining position, said connecting member being configured to beinserted into said slot in said inserting position and configured tocouple said first and second bands in said retaining position.